Extended roof reinforcement structure

ABSTRACT

This disclosure relates to a motor vehicle, and in particular a vehicle body structure for a motor vehicle, with an extended roof reinforcement structure. An example vehicle includes an A-pillar, a roof side rail, a dash panel, and a reinforcement structure extending at least partially through the roof side rail and the A-pillar to a front end forward of the dash panel.

TECHNICAL FIELD

This disclosure relates to a motor vehicle, and in particular a vehiclebody structure for a motor vehicle, with an extended roof reinforcementstructure.

BACKGROUND

Motor vehicles include doors configured to open and close relative toopenings in a body structure of the vehicle. Commonly, driver andfront-passenger doors are configured to open and close relative toopenings that are circumscribed by a sill, a hinge pillar, an A-pillar,a roof side rail, and a B-pillar. Some known vehicles includereinforcement structures within a roof side rail and an A-pillar.

SUMMARY

A motor vehicle according to an exemplary aspect of the presentdisclosure includes, among other things, an A-pillar, a roof side rail,a dash panel, and a reinforcement structure extending at least partiallythrough the roof side rail and the A-pillar to a front end forward ofthe dash panel.

In a further non-limiting embodiment of the foregoing motor vehicle, thereinforcement structure includes a first section extending from a rearend along a first axis to a curved section, and a second sectionextending from the curved section to the front end along a second axisinclined relative to the first axis.

In a further non-limiting embodiment of any of the foregoing motorvehicles, at least a segment of the second section is straight.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the front end is vertically below a top of a hinge pillar.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the front end is vertically below the top of the hinge pillarby about 95 mm.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure is a tube.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure is made using a roll-formingprocess.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure is made of a steel material.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure is made of a martensitic steel.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the first section is within the roof side rail.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the second section is partially within the A-pillar.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure is fastened to a side apron of themotor vehicle adjacent the front end.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure includes at least one aperturespaced rearward of the front end, and the at least one aperture isconfigured to receive a shank of a fastener.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the at least one aperture includes a plurality of apertures,and a front-most one of the plurality of apertures is accessible via ahood opening of the motor vehicle.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the reinforcement structure is a one-piece structure.

In a further non-limiting embodiment of any of the foregoing motorvehicles, the dash panel extends substantially normal to a centerline ofthe motor vehicle and provides a front boundary of a passenger cabin.

A vehicle body structure for a motor vehicle according to an exemplaryaspect of the present disclosure includes, among other things, areinforcement structure including a first section extending from a rearend to a curved section through a roof side rail along a first axis. Thereinforcement structure further includes a second section extending fromthe curved section to a front end through an A-pillar along a secondaxis inclined relative to the first axis. Further, the front end isforward of a dash panel.

In a further non-limiting embodiment of the foregoing body structure, atleast a segment of the second section is straight.

In a further non-limiting embodiment of any of the foregoing bodystructures, the front end is vertically below a top of a hinge pillar.

In a further non-limiting embodiment of any of the foregoing bodystructures, the reinforcement structure is a one-piece tube made of amartensitic steel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side-perspective view of an example body structure for amotor vehicle.

FIG. 2 is a side view of an example reinforcement structure.

FIG. 3 is a cross-sectional view taken along line 3-3 from FIG. 1, andillustrates an example manner in which the reinforcement structure ismounted to the body structure.

DETAILED DESCRIPTION

This disclosure relates to a motor vehicle, and in particular a vehiclebody structure for a motor vehicle, with an extended roof reinforcementstructure. An example vehicle includes an A-pillar, a roof side rail, adash panel, and a reinforcement structure extending at least partiallythrough the roof side rail and the A-pillar to a front end forward ofthe dash panel. The disclosed arrangement improves pillar stiffness andhelps absorb vehicle loads, and is particularly beneficial in vehicleswith relatively tight packaging constraints, such as vehicles with arelatively short hinge pillar. The reinforcement structure may also beformed using traditional manufacturing techniques and using relativelyhigh yield strength materials. These and other benefits will beappreciated from the below description.

FIG. 1 is a side-perspective view of a vehicle body structure 10 (“bodystructure 10”) for a motor vehicle (“vehicle”). The body structure 10includes, among other parts, a roof side rail 12, an A-pillar 14, aB-pillar 16, a hinge pillar 18 (which is sometimes referred to as anA-pillar tower reinforcement) configured to connect to a door hinge, anda sill 20. In FIG. 1, the roof side rail 12, A-pillar 14, B-pillar 16,hinge pillar 18, and sill 20 circumscribe an opening 22. Eventually, apassenger door is mounted to the hinge pillar 18 and is configured toselectively open and close relative to the opening 22. While thepassenger side of the body structure 10 is shown and described relativeto FIG. 1, it should be understood that the body structure 10 issubstantially symmetrical about its centerline C, and that the bodystructure 10 includes substantially similar structures on the driverside of the body structure 10.

Between the passenger and driver sides of the body structure 10, thebody structure 10 includes a dash panel 24, which includes a lengthdimension extending substantially normal to the centerline C. The dashpanel 24 is a component of the body structure 10 that provides a frontboundary of a passenger cabin 26. The “front” and “rear” directions arelabeled in FIG. 1 for ease of reference. In one example, the dash panel24 separates the passenger cabin 26 from an engine compartment. In otherexamples, such as when the body structure 10 is used in vehicles withoutan internal combustion engine, the dash panel 24 separates the passengercabin 26 from a motor compartment and/or a front trunk (“frunk”). Aninstrument panel may be mounted to the dash panel 24.

The body structure 10 includes at least one roof reinforcementstructure, and in particular both the passenger and driver sides of thebody structure 10 include a roof reinforcement structure. An examplereinforcement structure 28 is shown in FIG. 2 without the remainder ofthe body structure 10 for ease of reference. The term reinforcementstructure is not used herein as a nonce term, and is not intended toserve as a replacement for means. Rather, the term is used herein torefer to structures configured to reinforce the body structure 10. Tothis end, the reinforcement structure 28 may be referred to simply as areinforcement. In a particular example, the reinforcement structure 28may be referred to as a tube or a reinforcement tube.

In FIG. 2, the reinforcement structure 28 has a length dimensionincluding a first section 30 extending from a rear end 32 to a curvedsection 34. The curved section 34 may be a substantially gradual curve.The first section 30 is arranged within the roof side rail 12, in thisdisclosure. In an example, the first section 30 is connected to anotherportion of the body structure 10 using fasteners, such as bolts, screws,rivets, etc. The first section 30 is substantially straight and extendsalong a first axis A₁.

The length dimension of the reinforcement structure 28 further includesa second section 36 extending from the curved section 34 to a front end38 along a second axis A₂ which is inclined relative to the first axisA₁. In an aspect of this disclosure, the entire second section 36 isstraight. In other words, between the curved section 34 and the frontend 38, there are no curves or bends in the second section 36. Inanother aspect of this disclosure, the second section 36 issubstantially straight and a segment of the second section 36 betweenthe front end 38 and a point between the front end 38 and the curvedsection 34 is entirely straight. In either arrangement, forces appliedto the second section 36 are more effectively transferred rearwardly,along the length of the reinforcement structure 28, and absorbed by thebody structure 10.

The entire reinforcement structure 28, in one example, is formedseparately from the remainder of the body structure 10 and is formed asa one-piece structure. In one example, the reinforcement structure 28 isintegrally formed as a single, continuous structure. In a particularexample, the reinforcement structure 28 does not include any joints orseams, other than, in the example where the reinforcement structure 28is roll formed, a longitudinal seam extending along the entire length ofthe reinforcement structure 28. These arrangements reduce parts andeliminate manufacturing steps.

The reinforcement structure 28 is a hollow tube, in this example. Incross-section, the reinforcement structure 28 may be circular ornon-circular. As examples, the reinforcement structure 28 may beelliptical or stadium-shaped in cross-section. The reinforcementstructure 28 is formed by traditional manufacturing processes, such asroll forming. The curved section 34 may be formed by bending thereinforcement structure after it has been roll formed. Because thereinforcement structure 28 is formed by roll forming and bending asopposed to more complicated manufacturing techniques, such ashydroforming, and because the bend of the curved section 34 isrelatively gradual (i.e., not sharp), the reinforcement structure 28 maybe made of high yield strength materials. In one example, thereinforcement structure 28 is made of a high yield strength steel. In afurther example, the reinforcement structure is made of a martensiticsteel.

The front end 38 is the front-most end of the reinforcement structure28. In this disclosure, the reinforcement structure 28 is extendedrelative to known reinforcement structure such that, when thereinforcement structure 28 is mounted to the body structure 10, thefront end 38 is forward of (i.e., in front of, relative to the “front”direction) the dash panel 24, as shown in FIG. 3. The segment of thereinforcement structure 28 extending forward of the dash panel 24 isentirely straight in one example. In particular, the front end 38 liesin a plane that is spaced forward of a plane which contains the dashpanel 24. Further, the front end 38 is vertically below a top 40 of thehinge pillar 18. In one example the front end 38 is about 95 mm (3.74in) vertically below the top 40.

The placement of the front end 38 forward of the dash panel 24facilitates the transfer of loads rearwardly along the reinforcementstructure 28. Loads applied to the reinforcement structure 28 adjacentthe front end 38 are ultimately absorbed by the body structure 10adjacent the rear end 32. The placement of the front end 38 verticallybelow the top 40 of the hinge pillar 18 provides for added stiffness ofthe A-pillar 14, and reduces a bending moment which may otherwise formadjacent the top 40 (i.e., at a junction between the A-pillar 14 and thehinge pillar 18), which, in some situations, is not a suitable locationfor absorbing loads. With the present disclosure, loads are transferredalong the reinforcement structure 28 and absorbed by the body structure10 at more suitable locations. Arranging the front end 38 as in thispresent disclosure not only facilitates load transfer and improvesstiffness of the A-pillar, but also takes up less space adjacent thehinge pillar 18, which is beneficial in vehicles with a short (lowheight) hinge pillar, such as sport utility vehicles (SUVs) with arelatively high ground clearance.

The arrangement of the reinforcement structure 28 also facilitatesattachment of the reinforcement structure 28 to the body structure 10.As shown in FIG. 3, adjacent the front end 38, the reinforcementstructure 28 is attached to side apron 42 of the body structure 10. Thereinforcement structure 28 includes at least one aperture, and in thisexample includes first and second apertures 44, 46, spaced rearward(i.e., to the “rear” direction) of the front end 38 and configured toreceive a shank of a respective fastener 48, 50. The fasteners 48, 50may be bolts, screws, rivets, etc.

In the example of FIG. 3, at least the front-most aperture 44 isaccessible from forward of the dash panel 24 via a hood opening of thevehicle, which increases the ease of installing the reinforcementstructure 28, namely by increasing the ease of installing at least thefastener 48. In FIG. 3, the second aperture 46 is accessible fromrearward of the dash panel 24. This disclosure extends to other aperturearrangements. Further, the reinforcement structure 28 could be attachedto the body structure 10 by other techniques, such as welding.

It should be understood that terms such as “about,” “substantially,” and“generally” are not intended to be boundaryless terms, and should beinterpreted consistent with the way one skilled in the art wouldinterpret those terms. It should also be understood that directionalterms such as “front,” “rear,” “side,” etc., are used herein relative tothe normal operational attitude of a vehicle for purposes of explanationonly, and should not be deemed limiting.

Although the different examples have the specific components shown inthe illustrations, embodiments of this disclosure are not limited tothose particular combinations. It is possible to use some of thecomponents or features from one of the examples in combination withfeatures or components from another one of the examples. In addition,the various figures accompanying this disclosure are not necessarily toscale, and some features may be exaggerated or minimized to show certaindetails of a particular component or arrangement.

One of ordinary skill in this art would understand that theabove-described embodiments are exemplary and non-limiting. That is,modifications of this disclosure would come within the scope of theclaims. Accordingly, the following claims should be studied to determinetheir true scope and content.

1. A motor vehicle, comprising: an A-pillar; a roof side rail; a dashpanel; and a reinforcement structure extending at least partiallythrough the roof side rail and the A-pillar to a front end forward ofthe dash panel, wherein the reinforcement structure includes a firstsection extending from a rear end along a first axis to a curvedsection, and a second section extending from the curved section to thefront end along a second axis inclined relative to the first axis. 2.(canceled)
 3. The motor vehicle as recited in claim 1, wherein at leasta segment of the second section is straight.
 4. The motor vehicle asrecited in claim 1, wherein the front end is vertically below a top of ahinge pillar.
 5. The motor vehicle as recited in claim 4, wherein thefront end is vertically below the top of the hinge pillar by about 95mm.
 6. The motor vehicle as recited in claim 1, wherein thereinforcement structure is a tube.
 7. The motor vehicle as recited inclaim 6, wherein the reinforcement structure is made using aroll-forming process.
 8. The motor vehicle as recited in claim 7,wherein the reinforcement structure is made of a steel material.
 9. Themotor vehicle as recited in claim 8, wherein the reinforcement structureis made of a martensitic steel.
 10. The motor vehicle as recited inclaim 1, wherein the first section is within the roof side rail.
 11. Themotor vehicle as recited in claim 10, wherein the second section ispartially within the A-pillar.
 12. The motor vehicle as recited in claim11, wherein the reinforcement structure is fastened to a side apron ofthe motor vehicle adjacent the front end.
 13. The motor vehicle asrecited in claim 12, wherein: the reinforcement structure includes atleast one aperture spaced rearward of the front end, and the at leastone aperture is configured to receive a shank of a fastener.
 14. Themotor vehicle as recited in claim 13, wherein: the at least one apertureincludes a plurality of apertures, and a front-most one of the pluralityof apertures is accessible via a hood opening of the motor vehicle. 15.The motor vehicle as recited in claim 1, wherein the reinforcementstructure is a one-piece structure.
 16. The motor vehicle as recited inclaim 1, wherein the dash panel extends substantially normal to acenterline of the motor vehicle and provides a front boundary of apassenger cabin.
 17. A vehicle body structure for a motor vehicle,comprising: a reinforcement structure including a first sectionextending from a rear end to a curved section through a roof side railalong a first axis, the reinforcement structure further including asecond section extending from the curved section to a front end throughan A-pillar along a second axis inclined relative to the first axis, andwherein the front end is forward of a dash panel.
 18. The vehicle bodystructure as recited in claim 17, wherein at least a segment of thesecond section is straight.
 19. The vehicle body structure as recited inclaim 17, wherein the front end is vertically below a top of a hingepillar.
 20. The vehicle body structure as recited in claim 17, whereinthe reinforcement structure is a one-piece tube made of a martensiticsteel.